Brake Disc Surface Machining With Simultaneous Cutting and Rolling

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Solution Overview

Problem

The existing production methods for brake discs are inefficient, requiring a long production time due to sequential machining of brake surfaces, which limits both speed and surface quality.

Innovation Solution

A brake disc tool system that simultaneously machines both brake surfaces using paired cutting and forming tools, with an infeed device allowing for simultaneous cutting and forming, and a control unit for optimized rotation and tool movement, counterbalancing forces to minimize torque and axial bending.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If brake surfaces are machined sequentially (one after another), then the machining process is simple to control, but the production time is long

Engineering Contradiction:

Improveproduction timeVSAvoidtool system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines multiple machining operations (cutting and forming) on both brake surfaces into a single integrated tool system. The brake disc tool includes first and second cutting tools, first and second forming tools, and an infeed device that simultaneously machines both brake surfaces, thereby reducing production time while maintaining process control

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The tool system is segmented into independent but coordinated components: cutting tools for material removal, forming tools for surface formation, and an infeed device for synchronized movement. This segmentation allows each component to perform its function independently while contributing to the overall simultaneous machining process

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If forming tools press on brake surfaces from opposite sides, then rolling forces counterbalance each other preventing axial bending, but the tool system becomes more complex

Engineering Contradiction:

Improvesurface flatnessVSAvoidtool arrangement complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent employs symmetric tool arrangement where forming tools are positioned on opposite sides of the brake disc blank, creating balanced rolling forces that counteract each other. This symmetric configuration prevents axial bending and ensures uniform surface formation across both brake surfaces

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The forming tools on opposite sides act as counterbalancing elements, with their rolling forces serving as counterforces that neutralize each other. This counterbalancing effect prevents unwanted axial bending of the brake disc blank during the forming process, ensuring high surface quality

Inventive Principle:

Principle #8Anti-weight (Counterweight)

3Stability of the object's composition

If cutting tools are arranged to counterbalance passive forces, then torque on brake disc blank is minimized, but tool positioning becomes more difficult

Engineering Contradiction:

Improvebrake disc blank stabilityVSAvoidtool positioning ease

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The cutting tools are positioned symmetrically on opposite sides of the brake disc blank, creating a balanced configuration where passive forces and torques counterbalance each other. This symmetric arrangement minimizes net torque on the workpiece while maintaining ease of tool positioning and operation

Inventive Principle:

Principle #4Asymmetry

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach significantly reduces production time, enhances surface quality, and allows for greater pressure application during forming, resulting in a more efficient and high-quality brake disc manufacturing process.

Implementation Method 1

a first cutting tool (14) which is arranged to cut, in particular by way of turning, a first brake surface (34) of the brake disc blank (12)

Methodology Applied

Scientific EffectRotational machining:

Implementation Method 2

a first forming tool (18) for forming the first brake surface and a second forming tool (20) for forming, in particular flat-rolling or deep-rolling, the second brake surface (36)

Methodology Applied

Scientific EffectFlat-rolling:

Implementation Method 3

If the forming tools, especially in the form of flat-rolling or deep-rolling tools, press on the respective brake surface on a side which lies precisely opposite the other

Methodology Applied

Scientific EffectRolling pressure:

Implementation Method 4

the brake disc tool preferably has a cooling device that is connected to the smoothing tool

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11318538B2Brake disc tool for machining a brake disc blank, brake disc production plant and method for producing a brake disc

Publication Date: 2022.05.03 ECOROLL WERKZEUGTECHN

AI summary

A brake disc tool for machining a brake disc blank is provided. The brake disc tool includes a first cutting tool which is arranged to cut a first brake surface of the brake disc blank, a second cutting tool which is arranged to cut a second brake surface of the brake disc blank, a first forming tool for forming the first brake surface, a second forming tool for forming the second brake surface, and at least one infeed device for the infeed of the cutting tools and the forming tools towards one another, such that a brake disc blank arranged between the cutting tools and the forming tools is able to be machined and rolled in each case simultaneously on both of its brake surfaces.